Design and Analysis of Low-Cost BLDC Motor for Electric Vehicles

This study addresses the growing demand for efficient and reliable motor technologies in the shift toward electric vehicles (EV s). It presents the design of a Brushless DC (BLDC) hub motor optimized for small to mid-range EVs, specifically targeting urban mobility in resource-constrained regions. Achieving a high efficiency of 92<sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">%</sup>, the motor is validated through electromagnetic optimization using Ansys Motor-CAD V2023.1.1 simulations. The design focuses on minimizing energy losses, improving torque performance, and ensuring smooth operation with minimal noise and vibration. Utilizing standard materials such as N35UH magnets, the motor is compact, robust, and delivers 295 W of output power at a nominal speed of 330 RPM. Tailored for flat terrains and light commuting, it meets the performance requirements of sustainable electric mobility. The objective of this work is to provide a practical and efficient solution that bridges the gap between high performance and broad applicability in emerging markets, making it an ideal choice for resource-constrained regions.